Photovoltaic module mount

ABSTRACT

A photovoltaic module mounting system may include a module clamp that includes a central section that includes two first walls connected at the top of each first wall by a first connecting surface. The central section may have a first cross-sectional height corresponding to a height of each of the first walls and a first width corresponding to a distance between the two first walls. The module clamp may have ends that include two second walls connected at the top of each second wall by a second connecting surface in which each of the ends has a second cross-sectional height that is shorter than the first cross-sectional height and a second width that is wider than the first width. The central section may be connected to each of the ends such that the first connecting surface and the second connecting surface are bridged and form a bowtie shape.

The present disclosure generally relates to a photovoltaic module mountand a method of manufacturing the photovoltaic module mount.

BACKGROUND

Systems of solar panels may include one or more photovoltaic (PV)modules that convert sunlight into electrical power. The PV modules maybe mounted in rows on solar trackers that direct an orientation of thePV modules such that the orientation of the PV modules changesthroughout a day. For example, a series of piles may be disposed intothe ground and may support a torque tube to which the PV modules arecoupled. The PV modules may be coupled to the torque tube using a clamp,bolts (such as a U-bolt), or other coupling technique. As the torquetube is rotated under the direction of a solar tracker, the attached PVmodules rotate in a corresponding manner such that by changing theorientation of the torque tube, the PV modules are able to track thelocation of the sun throughout the day.

The subject matter claimed in the present disclosure is not limited toembodiments that solve any disadvantages or that operate only inenvironments such as those described above. Rather, this background isonly provided to illustrate one example technology area where someembodiments described in the present disclosure may be practiced.

SUMMARY

One or more embodiments of the present disclosure may include aphotovoltaic module mounting system that may include a module clamp thatincludes a central section that includes two first walls connected atthe top of each first wall by a first connecting surface. The centralsection may have a first cross-sectional height corresponding to aheight of each of the first walls and a first width corresponding to adistance between the two first walls. The module clamp may have endsthat include two second walls connected at the top of each second wallby a second connecting surface in which each of the ends has a secondcross-sectional height that is shorter than the first cross-sectionalheight and a second width that is wider than the first width. Thecentral section may be connected to each of the ends such that the firstconnecting surface and the second connecting surface are bridged andform a bowtie shape.

One or more embodiments of the present disclosure may include aphotovoltaic module mounting system in accordance with any of the otherembodiments of the present disclosure where each of the ends includesone or more slots configured to be aligned with one or more openings ofa photovoltaic module.

One or more embodiments of the present disclosure may include aphotovoltaic module mounting system in accordance with any of the otherembodiments of the present disclosure where the module clamp furtherincludes one or more flanges extending generally horizontally from oneor more of the first walls.

One or more embodiments of the present disclosure may include aphotovoltaic module mounting system in accordance with any of the otherembodiments of the present disclosure where the module clamp furtherincludes one or more flanges extending generally horizontally from oneor more of the ends.

One or more embodiments of the present disclosure may include aphotovoltaic module mounting system in accordance with any of the otherembodiments of the present disclosure where the module clamp furtherincludes one or more tabs protruding from the connecting surface in adirection towards which a photovoltaic module interfaces with the moduleclamp.

One or more embodiments of the present disclosure may include aphotovoltaic module mounting system in accordance with any of the otherembodiments of the present disclosure where the module clamp is made ofgalvanized steel.

One or more embodiments of the present disclosure may include aphotovoltaic module mounting system that may include a module clamp thatincludes a central section that includes two first walls connected at atop of each first wall by a first connecting surface. The centralsection may include a first cross-sectional height corresponding to aheight of each of the first walls and a first width corresponding to adistance between the two first walls. The module clamp may include oneor more ends that includes two second walls connected at a top of eachsecond wall by a second connecting surface in which each of the ends hasa second cross-sectional height that is shorter than the firstcross-sectional height and a second width that is wider than the firstwidth. The central section may be connected to each of the ends suchthat the first connecting surface and the second connecting surface arebridged and form a bowtie shape. The photovoltaic module mounting systemmay also include a torque tube band coupled to the module clamp.

One or more embodiments of the present disclosure may include aphotovoltaic module mounting system in accordance with any of the otherembodiments of the present disclosure where the channel includes acutout section that extends at least partially along a length of thechannel. In some embodiments, the cutout section may be wider in thecentral section and more narrow at either of the two ends.

One or more embodiments of the present disclosure may include aphotovoltaic module mounting system in accordance with any of the otherembodiments of the present disclosure where the module clamp includespivot fasteners coupling the torque tube band to the module clamp, thepivot fasteners spanning the cutout section.

One or more embodiments of the present disclosure may include aphotovoltaic module mounting system in accordance with any of the otherembodiments of the present disclosure where the first end and the secondend are each higher than the central section such that the mountingsurface forms a bowed shape from the first end to the central sectionand from the central section to the second end.

One or more embodiments of the present disclosure may include a methodthat includes obtaining a metal sheet coil, and cutting out a generallyrectangular patterned sheet from the metal sheet coil with length-sidesand width-sides. The generally rectangular patterned sheet may includecorresponding cutout portions on both of the length-sides, and thecutout portions may correspond to a profile of at least a portion of atorque tube. The method may also include forming the patterned sheetinto a module clamp from the patterned sheet, where the module clamp mayinclude a taller height in a central portion proximate the cutoutportions than at ends of the module clamp, and the module clamp mayinclude a width wider at the ends than at the central portion.

One or more embodiments of the present disclosure may include a methodin accordance with any of the other methods of the present disclosurewhere the metal sheet coil is made of galvanized steel.

One or more embodiments of the present disclosure may include a methodin accordance with any of the other methods of the present disclosurewhere the method may also include forming one or more slots in the endsof the module clamp, or in portions of the generally rectangularpatterned sheet that correspond to the ends of the module clamp.

One or more embodiments of the present disclosure may include a methodin accordance with any of the other methods of the present disclosurewhere the features formed on the module clamp may include one or moreprotruding tabs or one or more flanges formed along one or more surfacesof the module clamp.

One or more embodiments of the present disclosure may include a methodin accordance with any of the other methods of the present disclosurewhere forming the module clamp from the patterned sheet may includepositioning the patterned sheet against a contoured template block; andapplying force to the patterned sheet so that the patterned sheet takeson a shape complementing the contoured template block.

One or more embodiments of the present disclosure may include a methodin accordance with any of the other methods of the present disclosurewhere cutting out the patterned sheet from the metal sheet coil andforming the one or more slots in the patterned sheet may be performedsimultaneously.

One or more embodiments of the present disclosure may include a methodin accordance with any of the other methods of the present disclosurewhere cutting out the patterned sheet from the metal sheet coil andforming the one or more slots in the patterned sheet may be performedafter forming the one or more slots in the patterned sheet.

The object and advantages of the embodiments will be realized andachieved at least by the elements, features, and combinationsparticularly pointed out in the claims. It is to be understood that boththe foregoing general description and the following detailed descriptionare explanatory and are not restrictive of the invention, as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

Example embodiments will be described and explained with additionalspecificity and detail through the accompanying drawings in which:

FIG. 1A is an isometric view of an example embodiment of a PV modulemounting system, according to at least one embodiment of the presentdisclosure;

FIG. 1B is a front view of the example PV module mounting system of FIG.1A, according to at least one embodiment of the present disclosure;

FIG. 1C is a side view of the example PV module mounting system of FIG.1A, according to at least one embodiment of the present disclosure;

FIG. 2A is an isometric view of a second example embodiment of a PVmodule mounting system, according to at least one embodiment of thepresent disclosure;

FIG. 2B is a top-down view of the second example PV module mountingsystem of FIG. 2A, according to at least one embodiment of the presentdisclosure;

FIG. 2C is a side view of the second example PV module mounting systemof FIG. 2A, according to at least one embodiment of the presentdisclosure; and

FIG. 3 illustrates a flat pattern shape that may be used to form anexample PV module mounting system in a manufacturing process, accordingto at least one embodiment of the present disclosure

FIG. 4 is a flowchart of an example method of fabricating a PV modulemounting system, according to at least one embodiment of the presentdisclosure.

DETAILED DESCRIPTION

Different solar array sites may include varying environmentalconditions, such as different wind speeds, rainfall levels, snowfallfrequencies, other weather events, or some combination thereof.Depending on the weather events that affect a given solar array site,the pressure and stress experienced by photovoltaic (PV) modules at thegiven solar array site may greatly differ from the pressure and stressexperienced by PV modules located at other solar array sites.Additionally, different manufacturers or suppliers of PV modules mayhave differing strengths and characteristics, such that even in the samelocation, the amount of pressure and/or stress that can be sustained bydifferent PV modules can be observed. Also, different sizes of PVmodules may experience different stresses. For example, a smaller-sizedPV module may exert less stress on a support structure compared to alarger-sized PV module. PV module mounting assemblies may includedifferent types of structures that are geared towards handling thesedifferent pressure levels. For example, low-pressure PV module mountingassemblies may include fewer structural features that facilitatewithstanding high stress levels being exerted on the PV modules or thePV module mounting assemblies themselves. In comparison, PV modulemounting assemblies designed for high-pressure environments may includefeatures that improve resistance to high stress being exerted on the PVmodules or the PV module mounting assemblies.

The present disclosure relates to, among other things, a PV modulemounting system that is configured to be coupled with large format PVmodules and/or with smaller format PV modules in higher stresssituations (e.g., windy climates, climates with large amounts of snow,among others). In some embodiments, the PV module mounting system mayinclude a taller cross-section towards a middle of the PV modulemounting system and shorter cross-sections at the ends of the PV modulemounting system corresponding to differences in the stress profile oncethe PV module mounting system is coupled to a module rail of a PVmodule. Additionally or alternatively, the PV module mounting system mayinclude features that facilitate attachment of the module rail of the PVmodule to the PV module mounting system. For example, the PV modulemounting system may include one or more protruding tabs at flared endsthat facilitate spacing of gaps between PV modules. As another example,the PV module mounting system may include a lip or flange shape at oneor more edges of the flared ends that stabilize openings in the flaredends configured to interface with bolts that couple the PV modules tothe PV module mounting system. The above-mentioned features, along withvarious other factors, may facilitate usage of the PV module mountingsystem in high- or mid-pressure environments in which more robust PVmodule mounting features are used to withstand greater pressure loadsbut use of high-pressure components may be extraneous or too costly.Additionally or alternatively, such features may facilitate the use ofthinner materials in low-pressure applications, thereby reducing thecost of materials used in the mounting of PV modules in such acircumstance.

The PV module mounting system may be manufactured at a lower cost thanexisting PV module mounting assemblies because the PV module mountingsystem according to the present disclosure may be made using fewermaterials (or less material) than existing PV module mountingassemblies. Additionally or alternatively, the PV module mounting systemmay be formed using a progressive die stamping process that facilitatesmanufacturing the PV module mounting system with high throughput and atlarge production volumes. For example, the footprint of the metalcomponent used in manufacturing may include a base rectangular shapethat may significantly reduce the amount of wasted metal material whichmight otherwise occur in other shapes that provide for a tallercross-section towards a middle of the PV module mounting system.

Embodiments of the present disclosure are explained with reference tothe accompanying figures.

FIGS. 1A-1C illustrate different views of an example embodiment of a PVmodule mounting system 100 according to at least one embodiment of thepresent disclosure in which FIG. 1A shows an isometric view of the PVmodule mounting system 100. FIG. 1B is a front view of the PV modulemounting system 100 according to at least one embodiment of the presentdisclosure, and FIG. 1C is a side view of the PV module mounting system100 according to at least one embodiment of the present disclosure.

The PV module mounting system 100 may include a module clamp 110 onwhich a PV module (not shown) may be mounted. The module clamp 110 maybe coupled to a torque tube band 120 that is configured to circumscribea torque tube (not shown) in which rotation of the torque tube causesthe torque tube band 120 to rotate accordingly. The rotation of thetorque tube band 120 may result in a corresponding length-wise movementof the module clamp 110, which may in turn tilt the PV module mounted onthe module clamp 110. In other words, the PV module mounting system 100may be configured to control and/or adjust an orientation of a PV modulemounted on the PV module mounting system 100, such as for solar trackingor stowing the PV module during inclement weather conditions, based onrotation of a torque tube to which the PV module mounting system 100 iscoupled.

In some embodiments, the module clamp 110 may include a bow-tie shape inwhich one or more ends 111 a and 111 b (herein collectively referred toas “ends 111”) of the module clamp 110 are wider than a central section115 of the module clamp 110. Additionally or alternatively, the ends 111of the module clamp 110 may be shorter than the central section 115 suchthat the central section 115 has a narrower but taller profile thaneither of the ends 111. Because the central section 115 of the moduleclamp 110 may experience more stress than either of the ends 111 when aPV module is mounted on the PV module mounting system 100, the tallercross-section of the central section 115 may cause the central section115 to be more rigid in a vertical direction and capable of carryingstress from the weight of the PV module and/or other forces like wind orsnow than the shorter and wider ends 111.

In these and other embodiments, either or both of the ends 111 mayinclude one or more slots 114, holes, or other openings, that extendthrough the ends 111. The PV module may include one or more slotscorresponding to the slots 114 of the module clamp 110 such that the PVmodule may be coupled to the module clamp 110 by aligning the slots,holes, or other openings of the PV module with the slots 114 andinserting a bolt, a nut, a screw, any other types of fasteners, or somecombination thereof through the aligned slots. Although the module clamp110 is illustrated as including two slots 114 at each end 111 a and 111b, the module clamp 110 may include any number of slots 114. Forexample, each end 111 a and 111 b may include three, four, five, or moreslots 114 oriented at varying angles and spacings to facilitatealignment between the slots 114 and the slots of different PV modules.

Additionally or alternatively, either or both of the ends 111 mayinclude one or more tabs 113 that protrude from a top surface 112 of theends 111. A PV module coupled to the module clamp 110 may butt upagainst the tabs 113 to provide appropriate spacing between adjacent PVmodules. For example, the tabs 113 may provide spacing between the twoadjacent PV modules such that they do not contact each other and/or theslots 114 remain aligned with the holes in the PV modules.

In some embodiments, the module clamp 110 may include one or morewidth-wise flanges 117 a and/or one or more length-wise flanges 117 b(collectively referred to as “flanges 117”) that extend horizontallyfrom one or more lateral sides 116 of the module clamp 110. The flanges117 may include flat and/or curved portions of the lateral sides 116that extend horizontally from the lateral sides 116 in a width-wisedirection 118. The flanges 117 may facilitate distributing stressexperienced by the module clamp 110 and increase the load that themodule clamp 110 may carry (e.g., increase the maximum weight of the PVmodule that may be mounted on the PV module mounting system 100). Inthese and other embodiments, the flanges 117 may or may not extendaround the perimeter of the module clamp 110. For example, thewidth-wise flanges 117 a may not be present and extending in alength-wise direction from the ends 111 of the module clamp 110. Asanother example, the length-wise flanges 117 b may extend in thelength-wise direction from the ends 111, but the length-wise flanges 117b may not be connected to and continuous with respect to the width-wiseflanges 117 a. In these and other examples, having the flanges 117 notextending around the perimeter of the module clamp 110 and/or onlyextending in the width-wise direction 118 may reduce the material stressexperienced by the module clamp 110 caused by the weight of a PV modulecoupled to the module clamp 110 and/or caused by external environmentalfactors such as wind, snow, or other such factors. For example, in someembodiments, the length-wise flanges 117 b may begin at the end 111 aand proceed to the bottom surface 119 that interface with the torquetube, and may not extend through the portion of the module clamp 110corresponding to the bottom surface 119 that interface with the torquetube, and the length-wise flanges 117 b may begin again after theportion of the module clamp 110 corresponding to the bottom surface 119that interface with the torque tube and continue on to the end 111 b.While illustrated as being horizontal, it will be appreciated that theflanges 117 a/b may be slightly offset from horizontal, such as at 60°,70°, 80°, 85°, among others.

Modifications, additions, or omissions may be made to the module clamp110 without departing from the scope of the disclosure. For example, thedesignations of different elements in the manner described is meant tohelp explain concepts described herein and is not limiting. Further, themodule clamp 110 may include any number of other elements or may beimplemented within other systems or contexts than those described.

FIGS. 2A-2C illustrate different views of a second example embodiment ofa PV module mounting system 200 according to at least one embodiment ofthe present disclosure. FIG. 2A is an isometric view of the secondexample embodiment of the PV module mounting system 200 according to atleast one embodiment of the present disclosure. FIG. 2B is a top-downview of the second example embodiment of the PV module mounting system200 according to at least one embodiment of the present disclosure. FIG.2C is a side view of the second example embodiment of the PV modulemounting system 200 according to at least one embodiment of the presentdisclosure.

The PV module mounting system 200 may include a module clamp 210 onwhich a PV module (not shown) may be mounted. The module clamp 210 maybe coupled to a torque tube band 220 that is configured to circumscribea torque tube 230 in which rotation of the torque tube 230 causes acorresponding rotation of the torque tube band 220 and a correspondingtilting of the module clamp 210 and the PV module coupled to the moduleclamp 210.

A mounting surface 212 of the module clamp 210 that interfaces with thePV module may include a rectangular or a substantially rectangular shapethat includes a first end 211 a and a second end 211 b (collectivelyreferred to herein as “ends 211”) and a central section 215. In someembodiments, the module clamp 210 may include a channel 213 that extendsfrom the first end 211 a to the second end 211 b or substantially fromthe first end 211 a to the second end 211 b. The channel 213 mayincrease in depth as the channel 213 approaches the central section 215of the module clamp 210 so that the ends 211 may include shallowerheights than the central section 215 where the channel 213 is thedeepest. The central section 215 of the module clamp 210 may be morerigid and therefore capable of taking greater stress loads than the ends211 because the central section 215 is taller than either of the ends211.

In some embodiments, the module clamp 210 may be shaped so that the ends211 are positioned at a higher level than the central section 215 and aside profile of the module clamp 210 includes a bowed shape from thefirst end 211 a to the second end 211 b, such as shown in FIG. 2C. Thebowed shape of the module clamp 210 may increase the stress load themodule clamp 210 may be capable of handling and providing structuralsupport for the PV module coupled to the module clamp 210.

As described above in relation to the slots 114 of the module clamp 110in relation to FIGS. 1A-1C, the ends 211 of the module clamp 210 mayinclude one or more slots 214. The slots 214 may be aligned with one ormore slots or other fastening features of the PV module to facilitatecoupling of the PV module to the mounting surface 212 of the moduleclamp 210. In these and other embodiments, coupling the PV module to themodule clamp 210 may cause a bottom surface of the PV module tointerface with the ends 211 of the module clamp 210 while forming a gapbetween the bottom surface of the PV module and a bowed portion 216above the central section 215 of the module clamp 210.

In some embodiments, the module clamp 210 may include one or moreflanges 217 in which each flange 217 extends from an edge of the moduleclamp 210, such as from the width-wise edges at the ends 211 of themodule clamp 210. Additionally or alternatively, the flanges 217 mayextend from the length-wise edges of the module clamp 210. Like theflanges 117 described in relation to the module clamp 110 of FIG. 1 ,the flanges 217 may facilitate distribution of forces experienced by themodule clamp 210, which may increase the maximum allowable weight thatmay be carried by the PV module mounting system 200. In someembodiments, the flanges 217 b may correspond to a bottom surface 219that corresponds to the interface between the module clamp 210 and thetorque tube.

In some embodiments, the module clamp 210 may include a cutout section218 in the channel 213 and one or more pivot fasteners 222 that span atleast a width of the cutout section 218. The cutout section 218 may beincluded in the module clamp 210 to facilitate manufacturing of themodule camp 210 as described in relation to a flat pattern sheet 310 anda method 400 with respect to FIGS. 3 and 4 , respectively. The pivotfasteners 222 may span the width of the cutout section 218 to provideaxes about which a torque tube band 220 may rotate.

Modifications, additions, or omissions may be made to the module clamp210 without departing from the scope of the disclosure. For example, thedesignations of different elements in the manner described is meant tohelp explain concepts described herein and is not limiting. Further, themodule clamp 210 may include any number of other elements or may beimplemented within other systems or contexts than those described. Forexample, the module clamp 210 may include a tab similar or comparable tothe tabs 113 of FIGS. 1A-1C proximate the ends 211 a/21 b.

FIG. 3 illustrates one or more flat pattern sheets 310 that may be usedto form module clamps used in PV module mounting systems via a diestamping process 300 or other manufacturing process, according to atleast one embodiment of the present disclosure. In some embodiments, theflat pattern sheets 310 may be used to form the module clamp 110 and/orthe module clamp 210 as described in relation to FIGS. 1A-1C and 2A-2C,respectively. The flat pattern sheets 310 may include one or more cutoutportions 312 so that a module clamp formed from a given flat patternsheets 310 includes a clearance section configured to interface with atorque tube. For example, as illustrated in FIG. 3 , each of the cutoutportions 312 may include a trapezoidal or semi-hexagonal shape, whichmay facilitate interfacing a module clamp formed from the flat patternsheets 310 with a torque tube having a circular, square, oval,hexagonal, octagonal, nonagonal, or other cross-section shape. In theseand other embodiments, the cutout portions 312 may be located in anyposition to facilitate the interfacing of the module clamp with thetorque tube. For example, the cutout portions 312 may be located furthertowards either end of the flat pattern sheets 310.

The die stamping process 300 may include a sheet coil 305 that may becut into one or more of the flat pattern sheets 310. Each of the flatpattern sheets 310 may be input to the die stamping process 300, whichmay be a progressive die stamping procedure that is configured to formone or more features of a module clamp in a sequential process. In someembodiments, the die stamping process 300 may involve punching one ormore slots 320 into each of the flat pattern sheets 310 in one or moresteps in which each step may be performed by one or more sheet-metalprocessing machines. Additionally or alternatively, a channel 314 may bestamped or cut into the flat pattern sheet 310 that may correspond tothe cutout section 218 of FIGS. 2A-2C. In these and other embodiments,the die stamping process 300 may involve bending, folding, cutting,otherwise modifying the flat pattern sheets 310, or some combinationthereof in one or more steps with each step being performed by one ormore sheet-metal processing machines.

An example of the die stamping process 300 may include feeding the sheetcoil 305 to a first machine that cuts the sheet coil 305 to form one ormore of the flat pattern sheets 310. In some embodiments, cutting thesheet coil 305 to form a given flat pattern sheet 310 may involvecutting the sheet coil 305 a first distance along a length of the sheetcoil 305 to form width-wise sides 316 of the given flat pattern sheet310 and a second distance along a width of the sheet coil 305 to formlength-wise sides 318 of the given flat pattern sheet 310. The firstdistance that the sheet coil 305 is cut along its length may correspondto a size of the given flat pattern sheet 310 along its width-wise sides316, and the second distance may correspond to a size of the given flatpattern sheet 310 along its length-wise sides 318.

Each of the flat pattern sheets 310 may be processed by one or moresecond machines that are each configured to punch out or otherwise formone or more of the slots 320. Additionally or alternatively, the secondmachines may each be configured to cut one or more openings through theflat pattern sheets 310, such as the cutout section 218 included in themodule clamp 210 of FIGS. 2A-2C. The flat pattern sheets 310 includingthe slots 320 may be processed by one or more third machines that areeach configured to bend the flat pattern sheets 310 to form moduleclamps, such as the module clamp 110 or the module clamp 210. In thisand other examples, the module clamps may be fed to one or more fourthmachines that are each configured to modify the module clamp to form oneor more features of the module clamp, such as the flanges 117 of themodule clamp 110 and/or the flanges 217 of the module clamp 210.

While an example is provided of one order of operations to manufacture amodule clamp, it will be appreciated that these operations may beperformed in varying order. For example, the flat pattern sheets 310 maybe folded first and then have features cut out after the flat patternsheet 310 is folded. As another example, the flat pattern sheet 310 mayhave features cut out and then folded afterwards. Additionally oralternatively, such operations may be iteratively repeated or occur inany order. For example, one fold may be made, followed by one featurebeing cut out, followed by an additional fold being made, followed byanother feature being cut out, etc.

FIG. 4 is a flowchart of an example method 400 of fabricating the PVmodule mounting system according to at least one embodiment of thepresent disclosure. The method 400 may be performed by any suitablesystem, apparatus, or device. For example, any of the first machines,the second machines, the third machines, the fourth machines, and/or anyother apparatuses that may be implemented in a die stamping process likethe die stamping process 300 of FIG. 3 may perform one or moreoperations associated with the method 400. Although illustrated withdiscrete blocks, the steps and operations associated with one or more ofthe blocks of the method 400 may be divided into additional blocks,combined into fewer blocks, or eliminated, depending on the particularimplementation.

The method 400 may begin at block 402, where a metal sheet coil may beobtained. In some embodiments, the metal sheet coil may be a galvanizedsteel sheet, a carbon steel, an aluminum-steel alloy, or any other typesof metal. The metal sheet coil may be included in a roll of sheet metalthat is continuously fed to a metal-cutting apparatus included in aprogressive die stamping process. In some embodiments, because of thesimplified manufacturing disclosed in the present disclosure, the metalsheet coil may include a pre-treated (e.g., galvanized) material suchthat post-manufacturing treatment may not be required.

At block 404, a patterned sheet may be cut out from the metal sheetcoil. The patterned sheet may be cut from the metal sheet coil, such asby the metal-cutting apparatus into which the roll of sheet metal isfed, and a rectangular or substantially rectangular patterned sheet maybe cut from the metal sheet coil. The patterned sheet may include asubstantially rectangular shape with one or more cutouts, such as thecutout portions 312 as described in relation to FIG. 3 , to facilitateinterfacing a module clamp formed from the patterned sheet with acorresponding torque tube having a cross-sectional shape thatcorresponds to the shape of the cutouts. In some embodiments, one ormore edges of the metal sheet coil may be used as corresponding edges ofthe patterned sheet to decrease the amount of cutting used to form thepatterned sheet. For example, the patterned sheet may be cut from themetal sheet coil such that a length of the patterned sheet is the sameas or similar to a width of the metal sheet coil, and a width of thepatterned sheet corresponds to a segment of the length of the metalsheet coil when the metal sheet coil is fed into the metal-cuttingapparatus from the metal sheet coil's width-wise edge. Additionally oralternatively, the patterned sheet may be cut from the metal sheet coilas an individual shape as depicted in relation to the flat pattern shape310 of FIG. 3 .

At block 406, one or more slots may be formed in the patterned sheet. Insome embodiments, the slots may be formed as part of the progressive diestamping process being applied to the metal sheet coil and the patternedsheet. Thus, the slots may be formed simultaneously with the formationof the patterned sheet by cutting the metal sheet coil as described inrelation to block 404 or may be performed in a sequential processingstep before or after the formation of the patterned sheet. Additionallyor alternatively, the slots may be formed in the patterned sheet in agiven processing step subsequent to formation of the patterned sheet asdescribed in relation to block 404 in which the given processing stepsimultaneously includes formation of a module clamp as described inrelation to block 408.

Additionally or alternatively, forming the slots in the patterned sheetmay include forming one or more cutout features. For example, alength-wise slit may be cut into the center of the patterned sheet tocreate an opening in one or more surfaces of a module clamp formed fromthe patterned sheet, such as the cutout section 218 of the module clamp210 as described in relation to FIGS. 2A-2C.

At block 408, a module clamp may be formed from the patterned sheet. Insome embodiments, forming the module clamp may involve folding, bending,or otherwise changing the shape of the patterned sheet. In these andother embodiments, the shape of the module clamp may be changed bybending one or more portions of the patterned sheet. Additionally oralternatively, the patterned sheet may be pressed against a contouredtemplate block such that the patterned sheet is imprinted with thegeneral shape of the contoured template block and/or the shapes of anyprotruding features included with the contoured template block. Forexample, the patterned sheet may be placed flush against a rectangulartemplate block that includes a shorter width than the width of thepatterned sheet. The patterned sheet may be wrapped around therectangular template block in response to being pressed against therectangular template block, which may form a module clamp having arectangular channel shape.

At block 410, one or more features may be formed on the module clamp. Insome embodiments, the features formed on the module clamp may includeadditional or alternative bends in one or more portions of the moduleclamp, such as to form the flanges 117 and/or the flanges 217 of FIGS.1A-1C and/or FIGS. 2A-2C, respectively. Additionally or alternatively,the features formed on the module clamp may include protruding features,such as the tabs 113 of FIGS. 1A-1C, and/or additional cutout slots. Inthese and other embodiments, the features may be formed on the moduleclamp as part of the progressive die stamping process in which themodule clamp formed at block 408 is passed through one or moreforming/processing stations in which a forming tool at each of theforming stations is configured to form one or more of the features.

Modifications, additions, or omissions may be made to the method 400without departing from the scope of the disclosure. For example, thedesignations of different elements in the manner described is meant tohelp explain concepts described herein and is not limiting. Further, themethod 400 may include any number of other elements or may beimplemented within other systems or contexts than those described.Additionally or alternatively, one or more of the operations may becombined or performed simultaneously with others. The operations of themethod 400 may be performed in any order. For example, in someembodiments one or more of the cutting or forming steps 404 and/or 406may occur before or after one or more of the forming steps 408 and/or410. For example, the forming steps 408 and/or 410 may be performed,followed by the cutting step 404 and the forming step 406 in any order.Additionally or alternatively, such steps may be iteratively performed,such as forming, cutting, forming, cutting, or any other combination ofsuch steps.

Terms used in the present disclosure and especially in the appendedclaims (e.g., bodies of the appended claims) are generally intended as“open terms” (e.g., the term “including” should be interpreted as“including, but not limited to.”).

Additionally, if a specific number of an introduced claim recitation isintended, such an intent will be explicitly recited in the claim, and inthe absence of such recitation no such intent is present. For example,as an aid to understanding, the following appended claims may containusage of the introductory phrases “at least one” and “one or more” tointroduce claim recitations. However, the use of such phrases should notbe construed to imply that the introduction of a claim recitation by theindefinite articles “a” or “an” limits any particular claim containingsuch introduced claim recitation to embodiments containing only one suchrecitation, even when the same claim includes the introductory phrases“one or more” or “at least one” and indefinite articles such as “a” or“an” (e.g., “a” and/or “an” should be interpreted to mean “at least one”or “one or more”); the same holds true for the use of definite articlesused to introduce claim recitations.

In addition, even if a specific number of an introduced claim recitationis expressly recited, those skilled in the art will recognize that suchrecitation should be interpreted to mean at least the recited number(e.g., the bare recitation of “two recitations,” without othermodifiers, means at least two recitations, or two or more recitations).Furthermore, in those instances where a convention analogous to “atleast one of A, B, and C, etc.” or “one or more of A, B, and C, etc.” isused, in general such a construction is intended to include A alone, Balone, C alone, A and B together, A and C together, B and C together, orA, B, and C together, etc.

Further, any disjunctive word or phrase preceding two or morealternative terms, whether in the description, claims, or drawings,should be understood to contemplate the possibilities of including oneof the terms, either of the terms, or both of the terms. For example,the phrase “A or B” should be understood to include the possibilities of“A” or “B” or “A and B.”

All examples and conditional language recited in the present disclosureare intended for pedagogical objects to aid the reader in understandingthe present disclosure and the concepts contributed by the inventor tofurthering the art, and are to be construed as being without limitationto such specifically recited examples and conditions. Althoughembodiments of the present disclosure have been described in detail,various changes, substitutions, and alterations could be made heretowithout departing from the spirit and scope of the present disclosure.

1-7. (canceled)
 8. A photovoltaic module mounting system, comprising: amodule clamp that includes: a central section that includes two firstwalls connected at a top of each first wall by a first connectingsurface, the central section having a first cross-sectional heightcorresponding to a height of each of the first walls and a first widthcorresponding to a distance between the two first walls; and one or moreends that includes two second walls connected at a top of each secondwall by a second connecting surface in which each of the ends has asecond cross-sectional height that is shorter than the firstcross-sectional height and a second width that is wider than the firstwidth, wherein the central section is connected to each of the ends suchthat the first connecting surface and the second connecting surface arebridged and form a bowtie shape; and a torque tube band coupled to themodule clamp.
 9. The photovoltaic module mounting system of claim 8,wherein each of the ends includes one or more slots configured to bealigned with one or more openings of a photovoltaic module.
 10. Thephotovoltaic module mounting system of claim 8, wherein the module clampfurther includes one or more flanges extending generally horizontallyfrom one or more of the first walls.
 11. The photovoltaic modulemounting system of claim 8, wherein the module clamp further includesone or more flanges extending generally horizontally from one or more ofthe ends.
 12. The photovoltaic module mounting system of claim 8,wherein the module clamp further includes one or more tabs protrudingfrom the connecting surface in a direction towards which a photovoltaicmodule interfaces with the module clamp.
 13. The photovoltaic modulemounting system of claim 8, wherein the module clamp is made ofgalvanized steel.
 14. A photovoltaic module mounting system, comprising:a module clamp that includes: a central section that includes two firstwalls and a mounting surface connected to a horizontal planeperpendicular to the first walls, the central section having a firstcross-sectional height corresponding to a height of each of the firstwalls and a first width corresponding to a width of the mountingsurface; a first end and a second end in which the first end and thesecond end each has a second cross-sectional height that is shorter thanthe first cross-sectional height and a second width that is wider thanthe first width; and a channel extending from the first end to thesecond, including a cutout section that extends at least partially alonga length of the channel; and a torque tube band coupled to the moduleclamp.
 15. The photovoltaic module mounting system of claim 14, whereineach of the first end and the second end includes one or more slotsconfigured to be aligned with one or more openings of a photovoltaicmodule.
 16. The photovoltaic module mounting system of claim 14, whereinthe module clamp further includes one or more flanges extendinggenerally horizontally from one or more of the first walls.
 17. Thephotovoltaic module mounting system of claim 14, wherein the moduleclamp further includes one or more flanges extending from at least oneof the first end and the second end.
 18. The photovoltaic modulemounting system of claim 14, wherein the cutout section is widerproximate the central section as compared to proximate the first end.19. The photovoltaic module mounting system of claim 18, wherein themodule clamp includes pivot fasteners coupling the torque tube band tothe module clamp, the pivot fasteners spanning the cutout section. 20.The photovoltaic module mounting system of claim 14, wherein the firstend and the second end are each higher than the central section suchthat the mounting surface forms a bowed shape from the first end to thecentral section and from the central section to the second end.